MEINPRO

INDUSTRIAL PROCESS AND PLANT INSPECTION

INTRODUCTION TO
INDUSTRIAL PROCESS
 CHAPTER 1
OBJECTIVES
■ At the end of the chapter, the learner should
be able to:

– Identify concepts of industrial manufacturing process;

– Understand the principles of the different industrial
manufacturing process; and
– Learn the practical application of the different industrial
process in the field of manufacturing .
 INTRODUCTION TO
INDUSTRIAL PROCESS
“INDUSTRIAL MANUFACTURING PROCESSES”
INDUSTRIAL PROCESSES
- are procedures involving chemical, physical, electrical
or mechanical steps to aid in the manufacturing of an
item or items, usually carried out on a very large scale.
- may refer to a combination of operations for the sole
purpose of producing a product.

- the key components of heavy industry.

Chemical Mechanical
➢ Smelting ➢ Machining
➢ Disinfection ➢ Stamping
➢ Pyro Processing ➢ Forming
General Electrolysis
➢ Liquefaction of Gases ➢ Plating
➢ Super Critical Drying/ Freeze Drying ➢ Material Separating Metal
➢ Scrubber ➢ Electricity/Electrical
 - is a process of applying heat to ore in
order to extract a base metal. It is a form
of extractive metallurgy. It is used to extract
many metals from their ores,
including silver, iron, copper, and other base
metals.

Smelting uses heat and a chemical reducing

agent to decompose the ore, driving off other
elements as gases or slag and leaving the
metal base behind.
 is a process in which materials are
subjected to high temperatures (typically
over 800 °C) in order to bring about a
chemical or physical change.
Pyroprocessing includes such terms as ore-
roasting, calcination and sintering.
Equipment for pyroprocessing
includes kilns, electric arc
furnaces and reverberatory furnaces.
 is a process that generates a liquid from
a solid or a gas or that generates a non-
liquid phase which behaves in accordance
with fluid dynamics. It occurs
both naturally and artificially.
Example:
• "major commercial application of liquefaction is
the liquefaction of air to allow separation of the
constituents, such as oxygen, nitrogen, and the
noble gases."
• Another is the conversion of solid coal into a
liquid form usable as a substitute for liquid fuels.
 is a process to remove liquid in a
precise and controlled way. It is useful in
the production of microelectromechanical
systems (MEMS), the drying of spices, the
production of aerogel, the decaffeination of
coffee and in the preparation of biological
specimens for scanning electron
microscopy.
 are air pollution control
devices that use liquid to
remove particulate matter or
gases from an industrial
exhaust or flue gas stream.
This atomized liquid (typically
water) entrains particles and
pollutant gases in order to
effectively wash them out of
the gas flow
 is any of various processes in which a piece of
raw material is cut into a desired final shape and size by
a controlled material-removal process. The processes
that have this common theme, controlled material
removal, are today collectively known as subtractive
manufacturing, in distinction from processes of
controlled material addition, which are known
as additive manufacturing.

The three principal machining processes are classified

as turning, drilling and milling. Other operations falling
into miscellaneous categories include shaping, planing,
boring, broaching and sawing.
 is the process of placing flat sheet
metal in either blank or coil form into
a stamping press where a tool
and die surface forms the metal into a net
shape. Stamping includes a variety of sheet-
metal forming manufacturing processes,
such as punching using a machine
press or stamping press, blanking,
embossing, bending, flanging, and coining.
 is a process in which the shape
of a partly finished product,
for example sheet metal, is changed
using plastic deformation.
During forming, force is applied to a
piece of sheet metal to change its
shape rather than remove any
material.
 is the process of plating one metal onto
another by hydrolysis, most commonly for decorative
purposes or to prevent corrosion of a metal. There
are also specific types of electroplating such as
copper plating, silver plating, and chromium plating.
Electroplating allows manufacturers to use
inexpensive metals such as steel or zinc for the
majority of the product and then apply different
metals on the outside to account for appearance,
protection, and other properties desired for the
product. The surface can be a metal or even plastic.
 INTRODUCTION TO
INDUSTRIAL PROCESS
“MANUFACTURING”
WHAT IS MANUFACTURING?
The word manufacture is derived from two Latin words, manus
(hand) and factus (make); the combination means made by hand. The
English word manufacture is several centuries old, and ‘‘made by
hand’’ accurately described the manual methods used when the word
was first coined. Most modern manufacturing is accomplished by
automated and computer-controlled machinery.

❖As a field of study in the modern context, manufacturing can be

defined two ways, one technologic and the other economic.
MANUFACTURING
Technologically, manufacturing is the
application of physical and chemical
processes to alter the geometry,
properties, and/or appearance of a given
starting material to make parts or
products; manufacturing also includes
assembly of multiple parts to make
products. The processes to accomplish
manufacturing involve a combination of
machinery, tools, power, and labor, as
depicted in Figure 1.1(a). Manufacturing is
almost always carried out as a sequence of
operations. Each operation brings the Figure 1.1 (a) as a technical process
material closer to the desired final state.
MANUFACTURING
Economically, manufacturing is the
transformation of materials into items of
greater value by means of one or more
processing and/or assembly operations,
as depicted in Figure1.1(b).The key point
is that manufacturing adds value to the
material by changing its shape or
properties, or by combining it with other
materials that have been similarly
altered. The material has been made
more valuable through the
manufacturing operations performed on Figure 1.1 (b) as an economic process
it.
 Two ways to define manufacturing

(a) as a technical process (b) as an economic process

Manufacturing is an important commercial activity performed by
companies that sell products to customers. The type of
manufacturing done by a company depends on the kind of product
it makes.
MANUFACTURING INDUSTRIES
- Industry consists of enterprises and organizations that produce or supply
goods and services

Industry classifications:
Primary industries - cultivate and exploit natural resources, such as agriculture
and mining
Secondary industries - take the outputs of the primary industries and convert them
into consumer and capital goods (Manufacturing is the principal
activity in this category, but construction and power utilities are
also included. )
Tertiary industries - constitute the service sector of the economy
 MANUFACTURED PRODUCTS

Two Major Classes of Final Products

Consumer goods products purchased directly by consumers, such
as cars, personal computers, TVs, tires, and tennis
rackets

Capital goods purchased by companies to produce goods and/or

provide services like aircraft, computers,
communication equipment, medical apparatus,
trucks and buses, railroad locomotives, machine
tools, and construction equipment
PRODUCTION QUANTITY AND PRODUCT VARIETY
The quantity of products made by a factory has an important
influence on the way its people, facilities, and procedures are
organized.

Annual production quantities can be classified into three ranges:

(1) low production, quantities in the range 1 to 100 units per year
(2) medium production, from100to10,000 units annually
(3) high production, 10,000 to millions of units.
• Production quantity refers to the
number of units produced annually
of a particular product type.
• Product variety refers to different
product designs or types that are
produced in the plant. Different
products have different shapes and
sizes; they perform different
functions; they are intended for
different markets; some have more
components than others; so on
and so forth.
There is an inverse correlation
between product variety and
production quantity in terms of
factory operations. If a factory’s
product variety is high, then its
production quantity is likely to be low;
but if production quantity is high, then
product variety will be low, as
depicted in the figure. Manufacturing
plants tend to specialize in a
combination of production quantity
and product variety that lies
somewhere inside the diagonal band
in the figure.
MANUFACTURING CAPABILITY
refers to the technical and physical limitations of a manufacturing
firm and each of its plants. Several dimensions of this capability can
be identified: (1) technological processing capability, (2) physical
size and weight of product, and (3) production capacity.

MANUFACTURING PLANT
➢ consists of a set of materials, processes and systems
(and people, of course)
➢ designed to transform a certain limited range of
materials into products of increased value
Technological - The technological processing capability of a
plant (or company) is its available set of manufacturing
Processing processes.
Capability
- closely related to material type

- Technological processing capability includes not only

the physical processes, but also the expertise
possessed by plant personnel in these processing
technologies.
- Companies must concentrate on the design and
manufacture of products that are compatible with their
technological processing capability.
Physical Product
Limitations
- A second aspect of manufacturing capability is imposed by
the physical product. A plant with a given set of processes is
limited in terms of the size and weight of the products that can
be accommodated.
Production Capacity
- A third limitation on a plant’s manufacturing capability is the
production quantity that can be produced in a given time period
(e.g., month or year).This quantity limitation is commonly called
plant capacity, or production capacity, defined as the maximum
rate of production that a plant can achieve under assumed
operating conditions.
The words manufacturing and production are often used
interchangeably. But production has a broader meaning
than manufacturing.
To illustrate, one might speak of ‘‘crude oil production,’’
but the phrase ‘‘crude oil manufacturing’’ seems out of
place. Yet when used in the context of products such as
metal parts or automobiles, either word seems okay.
End…
• Human factors in process plant operation by Strobhar, David A. c2014
• Fundamentals of Modern Manufacturing; Materials, Processes, and
Systems 6th Edition, Mikell P. Groover, c2015
• Fundamental of Industrial Instrumentation and Process Control 2 nd Edition
c2018
• Overview of industrial process automation by K.L.S. Sharma -- Waltham,
MA: Elsevier, Inc., c2011
• Manufacturing processes: materials, productivity, and lean strategies by
John Barry DuVall, David R. Hillis -- Tinley Park, Ill.: Goodheart-Willcox,
c2012.
• Manufacturing facilities design and material handling by Fred E. Meyers,
Matthew P. Stephens -- Upper Saddle River, NJ: Pearson, c2005
 MEINPRO
INDUSTRIAL PROCESS AND PLANT INSPECTION

BASIC AND APPLICATIONS OF

INDUSTRIAL PROCESS
 CHAPTER 2
OBJECTIVES
■ At the end of the chapter, the learner should
be able to:

– Identify the different materials and manufacturing

processes;
– Understand the different manufacturing process; and
– Learn and understand Production system.
 BASIC AND APPLICATIONS OF
INDUSTRIAL PROCESS
“MATERIALS AND MANUFACTURING PROCESSES”
MATERIALS IN MANUFACTURING

Most engineering materials can be classified into one of three

basic categories: (1)metals, (2) ceramics, and (3) polymers.
Their chemistries are different, their mechanical and
physical properties are different, and these differences affect
the manufacturing processes that can be used to produce
products from them.
In addition to the three basic categories, there are (4)
composites — nonhomogeneous mixtures of the other three
basic types rather than a unique category.
METALS

Metals used in manufacturing are usually alloys, which are

composed of two or more elements, with at least one being a
metallic element. Metals and alloys can be divided into two
basic groups: (1) ferrous and (2) nonferrous.
METALS

Ferrous Metals - are based on iron; the group includes steel and
cast iron.
Steel can be defined as an iron–carbon alloy containing
0.02% to 2.11% carbon.

Cast iron is an alloy of iron and carbon (2% to 4%) used in

casting (primarily sand casting). Silicon is also present in
the alloy (in amounts from 0.5% to 3%), and other
elements are often added also, to obtain desirable
properties in the cast part.
METALS

Nonferrous Metals - include the other metallic elements and

their alloys. In almost all cases, the alloys are more important
commercially than the pure metals. The nonferrous metals
include the pure metals and alloys of aluminum, copper, gold,
magnesium, nickel, silver, tin, titanium, zinc, and other metals.
CERAMICS

- is defined as a compound containing metallic (or semi-

metallic) and nonmetallic elements. Typical nonmetallic
elements are oxygen, nitrogen, and carbon. Ceramics include a
variety of traditional and modern materials.
CERAMICS

Traditional ceramics, some of which have been used for

thousands of years, include:
clay - (abundantly available, consisting of fine particles of
hydrous aluminum silicates and other minerals used in making
brick, tile, and pottery);
silica – (the basis for nearly all glass products); and
alumina and silicon carbide – (two abrasive materials used in
grinding).
CERAMICS

Modern ceramics - include some of the preceding materials,

such as alumina, whose properties are enhanced in various
ways through modern processing methods.
Newer ceramics include:
carbides—metal carbides such as tungsten carbide and titanium
carbide, which are widely used as cutting tool materials; and
nitrides—metal and semimetal nitrides such as titanium nitride
and boron nitride, used as cutting tools and grinding abrasives.
POLYMERS

- is a compound formed of repeating structural units called

mers, whose atoms share electrons to form very large
molecules. Polymers usually consist of carbon plus one or more
other elements, such as hydrogen, nitrogen, oxygen, and
chlorine.
Polymers are divided into three categories:
(1) thermoplastic polymers,
(2) thermosetting polymers, and
(3) elastomers.
POLYMERS
Thermoplastic polymers - can be subjected to multiple heating and
cooling cycles without substantially altering themolecular structure of
the polymer. Common thermoplastics include polyethylene,
polystyrene, polyvinylchloride, and nylon.
Thermosetting polymers - chemically transform (cure) into a rigid
structure on cooling from a heated plastic condition; hence the name
thermosetting. Members of this type include phenolics, amino resins,
and epoxies. Although the name thermosetting is used, some of
these polymers cure by mechanisms other than heating.
Elastomers - are polymers that exhibit significant elastic behavior;
hence the name elastomer. They include natural rubber, neoprene,
silicone, and polyurethane.
COMPOSITES
- is a material consisting of two or more phases that are
processed separately and then bonded together to achieve
properties superior to those of its constituents. The term phase
refers to a homogeneous mass of material, such as an
aggregation of grains of identical unit cell structure in a solid
metal. The usual structure of a composite consists of particles or
fibers of one phase mixed in a second phase, called the matrix.
 MANUFACTURING PROCESSES
- is a designed procedure that results in
physical and/or chemical changes to a starting
work material with the intention of increasing
the value of that material.
- is usually carried out as a unit operation,
which means that it is a single step in the
sequence of steps required to transform the
starting material into a final product.
- are the steps through which raw materials are transformed into a final product
- begins with the creation of the materials from which the design is made. These
materials are then modified through manufacturing processes to become the required
part.
 MANUFACTURING PROCESSES
A processing operation transforms a work
material from one state of completion to a more
advanced state that is closer to the final desired
product. It adds value by changing the geometry,
properties, or appearance of the starting
material. In general, processing operations are
performed on discrete work parts, but certain
processing operations are also applicable to
Manufacturing operations can assembled items (e.g., painting a spot-welded
be divided into two basic types: car body). An assembly operation joins two or
(1) processing operations and more components to create a new entity, called
(2) assembly operations. an assembly, subassembly, or some other term
that refers to the joining process.
PROCESSING OPERATIONS
A processing operation uses energy to alter a work part’s shape,
physical properties, or appearance to add value to the material. The forms
of energy include mechanical, thermal, electrical, and chemical. The energy
is applied in a controlled way by means of machinery and tooling. Human
energy may also be required, but the human workers are generally
employed to control the machines, oversee the operations, and load and
unload parts before and after each cycle of operation
PROCESSING OPERATIONS
Shaping operations - alter the geometry of the starting work material by
various methods. Common shaping processes include casting, forging, and
machining.
Property-enhancing operations - add value to the material by improving its
physical properties without changing its shape. Heat treatment is the most
common example.
Surface processing operations - are performed to clean, treat, coat, or
deposit material onto the exterior surface of the work. Common examples
of coating are plating and painting.
ASSEMBLY OPERATIONS
The second basic type of manufacturing operation is assembly, in which two or more
separate parts are joined to form a new entity. Components of the new entity are
connected either permanently or semi permanently.
Permanent joining processes - include welding, brazing, soldering, and adhesive bonding.
They form a joint between components that cannot be easily disconnected.

Mechanical assembly - methods are available to fasten two (or more) parts together in a
joint that can be conveniently disassembled. The use of screws, bolts, and other
threaded fasteners are important traditional methods in this category. Other mechanical
assembly techniques form a more permanent connection; these include rivets, press
fitting ,and expansion fits.
BASIC AND APPLICATIONS OF
INDUSTRIAL PROCESS
“PRODUCTION SYSTEM”
 PRODUCTION SYSTEMS
-To operate effectively, a manufacturing
firm must have systems that allow it to
efficiently accomplish its type of
production.
-Production systems consist of people,
equipment, and procedures designed for
the combination of materials and
processes that constitute a firm’s
manufacturing operations.
 PRODUCTION SYSTEM
- can be divided into two categories: (1) production facilities and (2)
manufacturing support systems, as shown in figure .
PRODUCTION SYSTEM
Production facilities - refer to the physical equipment and the
arrangement of equipment in the factory.
Manufacturing support systems - are the procedures used by the
company to manage production and solve the technical and logistics
problems encountered in ordering materials, moving work through the
factory, and ensuring that products meet quality standards.

Both categories include people. People make these systems work. In

general, direct labor workers are responsible for operating the
manufacturing equipment; and professional staff workers are responsible
for manufacturing support.
PRODUCTION FACILITIES
Production facilities - consist of the factory and the production,
material handling, and other equipment in the factory.
The equipment comes in direct physical contact with the parts
and/or assemblies as they are being made. The facilities
‘‘touch’’ the product. Facilities also include the way the
equipment is arranged in the factory— the plant layout. The
equipment is usually organized into logical groupings; which can
be called manufacturing systems, such as an automated
production line, or a machine cell consisting of an industrial
robot and two machine tools.
WHAT IS PLANT LAYOUT?
- is a systematic and efficient functional arrangement of various
departments, machines, tools, equipment and other supports services
of an industrial organization, that will facilitate the smooth processing
of the proposed or undertaken product in the most effective, most
efficient and most economical manner in the minimum possible time.

❖ Good plant layout comprises of best possible arrangement of the

buildings, men, machine and materials for processing a under taken
product.
OBJECTIVES OF GOOD PLANT LAYOUT
The main objectives of a good plant layout involves:
• minimum material movement,
• smooth flow of the product in the plant,
• full utilization of the space of the plant,
• provide adequate safety and satisfaction to the plant workers,
• evolve sufficient flexibility in the arrangement of the above
factors so as to suit the minor future changes, and
• facilitates an effective supervision.
TYPES OF LAYOUTS
a. Fixed Position layout,
b. Process or Functional
layout
c. Cellular Layout
combination or group
layout
d. Line or Product layout,
FIXED POSITION LAYOUT
• In this type of layout the major part of an assembly or material
remains at a fixed position. All its accessories, auxiliary material,
machinery, equipment needed, tools required, and the labor are
brought to the fixed site to work.
 FIXED POSITION LAYOUT
Advantages: Disadvantages:
1. Layout is highly flexible for varieties of products 1. The cost of equipment handling is
having intermittent demand as the type of very high.
product and the related processes can be easily 2. Labors and equipment's are difficult
altered without any change in the layout. to utilize fully.
2. There is a minimum movement of men, material, 3. It is limited to large items only.
and tooling during manufacturing process.
3. The material is drastically reduced.
4. Highly skilled operators are required to complete
the work at one point and responsibility for
quality is fixed on one person or the assembly
crew.
5. Every personnel of manufacturing team is
responsible for quality work for manufacturing the
product.
PROCESS OR FUNCTIONAL LAYOUT
• In this type of layout arrangements of similar machines,
production facilities and manufacturing operations are grouped
together according to their functions.
 PROCESS OR FUNCTIONAL LAYOUT
Advantages: Disadvantages:
1. There exists a wide flexibility regarding 1. This layout requires more space in comparison to line
allotment of work to equipment and workers. or product layout for the same amount of production.
2. There is a better utilization of the available 2. Production control becomes relatively difficult in this
equipment. layout.
3. Comparatively less numbers of machines are 3. Raw material has to travel more which increases
needed in this layout and hence thus reducing material handling and the associated costs.
capital investment. 4. This layout requires more efficient co-ordination and
4. There is an improved product quality, because inspections.
the supervisors and workers attend to one type 5. Increased material handling cost due to more
of machines and operations. movement of process raw material to various paths
5. Varieties of jobs coming as different job orders 6. More material in process remains in queue for further
thus make the work more interesting for the operations.
workers. 7. Requires large in-process inventory.
6. Workers in one section are not affected by the 8. Completion of same product takes more time.
nature of the operations carried out in another
section. For example, a lathe operator is not
affected by the rays of the welding as the two
sections are quite separate.
CELLULAR LAYOUT
• In this layout the manufacturing system is configure so that
groups of similar products can be made on the same equipment
without significant lost time because of setup. The processing or
assembly of different parts or products is accomplished in cells
consisting of several workstations or machines.
LINE OR PRODUCT LAYOUT
• This layout implies that various operations on raw material are
performed in a sequence and the machines are placed along the
product flow line, i.e., machines are arranged in the sequence in
which the raw material will be operated upon.
 PROCESS OR FUNCTIONAL LAYOUT
Advantages: Disadvantages:
1. It involves smooth and continuous work flow. 1. It is very difficult to increase production beyond
2. It may require less skilled workers the capacities of the production lines.
3. It helps in reducing inventory. 2. When single inspector has to look after many
4. Production time is reduced in this layout. machines, inspection becomes difficult
3. This layout is very less flexible for product change.
5. Better coordination, simple production planning
and control are achieved in this layout. 4. The rate or pace rate of working depends upon
the output rate of the slowest machine and hence
6. For the same amount of production, less space
requirements for this layout. leading to excessive idle time for other machines if
the production line is not adequately balanced.
7. Overall processing time of product is very less.
5. Machines being put up along the line, more
8. This layout involves automatic material
machines of each type have to be installed for
handling, lesser material movements and hence
leads to minimum possible cost of keeping a few as stand by, because if on machine
manufacturing. in the line fails, it may lead to shut down of the
complete production line. That is why the line or
product layout involves heavy capital investments.
MANUFACTURING SUPPORT SYSTEM
To operate its facilities efficiently, a company must organize itself to
design the processes and equipment, plan and control the production
orders, and satisfy product quality requirements. These functions are
accomplished by manufacturing support systems— people and
procedures by which a company manages its production operations.
Most of these support systems do not directly contact the product,
but they plan and control its progress through the factory. Manufacturing
support functions are often carried out in the firm by people organized
into departments such as the following:
MANUFACTURING SUPPORT SYSTEM
Manufacturing engineering – This department is responsible for planning
the manufacturing processes —(deciding what processes should be used
to make the parts and assemble the products). This department is also
involved in designing and ordering the machine tools and other
equipment used by the operating departments to accomplish processing
and assembly.
Production planning and control – this department is responsible for
solving the logistics problem in manufacturing —(ordering materials and
purchased parts, scheduling production, and making sure that the
operating departments have the necessary capacity to meet the
production schedules).
MANUFACTURING SUPPORT SYSTEM
Quality control – Producing high-quality products should be a top priority
of any manufacturing firm in today’s competitive environment. It means
designing and building products that conform to specifications and satisfy
or exceed customer expectations. Much of this effort is the responsibility
of the QC department.
End…
• Human factors in process plant operation by Strobhar, David A. c2014
• Fundamentals of Modern Manufacturing; Materials, Processes, and
Systems 6th Edition, Mikell P. Groover, c2015
• Fundamental of Industrial Instrumentation and Process Control 2 nd Edition
c2018
• Overview of industrial process automation by K.L.S. Sharma -- Waltham,
MA: Elsevier, Inc., c2011
• Manufacturing processes: materials, productivity, and lean strategies by
John Barry DuVall, David R. Hillis -- Tinley Park, Ill.: Goodheart-Willcox,
c2012.
• Manufacturing facilities design and material handling by Fred E. Meyers,
Matthew P. Stephens -- Upper Saddle River, NJ: Pearson, c2005
 MEINPRO
INDUSTRIAL PROCESS AND PLANT INSPECTION

METHODS, PROCESSES AND

EQUIPMENT INVOLVED IN
HANDLING OF SOLIDS
 CHAPTER 3
OBJECTIVES
■ At the end of the chapter, the learner should
be able to:

– Identify different concepts involved in handling solids; and

– Understand the methods, processes and equipment involved
in handling solids.
METHODS, PROCESSES AND
EQUIPMENT INVOLVED IN
HANDLING OF SOLIDS
“FEEDERS AND SILOS”
MATERIAL HANDLING
➢Involves short-distance movement that usually takes place within
the confines of a building such as a plant or a warehouse and
between a building and a transportation agency

➢It can be used to create “time and place utility” through the
handling, storage, and control of material, as distinct from
manufacturing (i.e., fabrication and assembly operations), which
creates “form utility” by changing the shape, form, and makeup of
material
 TEN PRINCIPLES OF MATERIAL HANDLING
as compiled by the College-Industry Council on Material Handling Education (CIC-MHE) in cooperation
with the Material Handling Institute (MHI), represent the distillation of many years of accumulated experience
and knowledge of many practitioners and students of material handling
1. Planning Principle. All material handling should be the result of a deliberate plan where the
needs, performance objectives, and functional specification of the proposed methods are
completely defined at the outset.
2. Standardization Principle. material handling methods, equipment, controls and software should
be standardized within the limits of achieving overall performance objectives and without
sacrificing needed flexibility, modularity, and throughput.
3. Work Principle. material handling work (defined as material flow multiplied by the distance
moved) should be minimized without sacrificing productivity or the level of service required of
the operation.
4. Ergonomic Principle. Human capabilities and limitations must be recognized and respected in the
design of material handling tasks and equipment to ensure safe and effective operations.
5. Unit Load Principle. Unit loads shall be appropriately sized and configured in a way that achieves
the material flow and inventory objectives at each stage in the supply chain.
6. Space Utilization Principle. Effective and efficient use must be made of all available (cubic) space.
7. System Principle. Material movement and storage activities should be fully integrated to form a
coordinated, operational system which spans receiving, inspection, storage, production,
assembly, packaging, unitizing, order selection, shipping, and transportation, and the handling of
returns.
8. Automation Principle. material handling operations should be mechanized and/or automated
where feasible to improve operational efficiency, increase responsiveness, improve consistency
and predictability, decrease operating costs, and to eliminate repetitive or potentially unsafe
manual labor.
9. Environmental Principle. Environmental impact and energy consumption should be considered as
criteria when designing or selecting alternative equipment and material handling system.
10. Life Cycle Cost Principle. A thorough economic analysis should account for the entire life cycle of
all material handling equipment and resulting systems.
STORAGE SILOS
➢ is a structure for storing bulk materials. Silos are used in agriculture to
store grain or fermented feed known as silage. Silos are more commonly
used for bulk storage of grain, coal, cement, carbon black, woodchips,
food products and sawdust.
Three types of silos are in widespread use today:
• tower silos
• bunker silos
• bag silos

➢Missile silos are used for the storage and launching of ballistic
missiles.
➢Bin
TYPES OF SILOS

Tower Silos

• most common type of silo

• can be made of concrete, brick,
metal, wood, and other
materials
• loading and unloading is done
with automated systems
TYPES OF SILOS
Bunker Silos

• are trenches, usually with concrete

walls,
• covered with a plastic tarp to make it
airtight
• automated systems for loading and
unloading
• more low profile than tower silos
• better insulated
TYPES OF SILOS

Bag silos

• 8 to 12 ft in diameter
• unloaded using a tractor and
loader or skid-steer loader.
• require little capital investment.
• temporary measure when growth
or harvest conditions require more
space.
TYPES OF SILOS
Bins
• shorter than a silo
• used for holding dry matter
• shape is either round or squared
• contain a hollow perforated or
screened central shaft
CONSTRUCTION TYPE
The construction types of silos are:
• Flat Bottom Silos
• Hopper Bottom Silos
• Smooth Wall Silos
• Stainless Steel Silos
• Corrugated Steel Silos
• Bolted & Welded Steel Silos
• Tower Silos
• Transportable Silos
• Lipp Silo
FEEDERS
➢are machineries used in assembly and
manufacturing applications to move or
“transport” materials or products to a
designated storage or to other processing
equipment.
➢are devices mounted at the outlet of
storage units such as bins, bunkers, silos or
hoppers which are used to control and
meter the flow of bulk materials from the
storage unit to meet the specified
discharge flow rate.
Types of
Feeders
ROTARY FEEDER
• rotating element or vane
discharges powder or
granules at a predetermined
rate
• often used with large
amounts of solid material
• power comes from an
internal combustion engine
or an electrical motor
VIBRATORY FEEDERS
• use both vibration and gravity to
move material
• used to transport a large number
of smaller objects
• uncontrolled recovery of the
material from top of feeder
• controlled delivery of the material
from bottom of feeder
How It Works?
Example: PILL BOTTLING SYSTEM
• a large batch of pills is dumped into
the top of the vibratory feeder.
• gravity will pull the pills toward the
bottom of the feeder where they can
exit one at a time so that they can
be counted.
• once the correct number is in the
container, the feed is stopped until a
new bottle is placed in position.
 SCREW FEEDERS
• used for handling bulk materials, in which
a rotating helicoid screw moves the
material forward, toward and into a
process unit.
• very similar to screw conveyors in their
basic structure, both of which are based
on the principles of the Archimedean
screw.
• capable of delivering dense slurries and
dry granular products with great accuracy
at a range of operational speeds.
• drive is controlled by servo motors capable
of precise stop-start and speed control.
VOLUMETRIC SCREW FEEDERS
• amount of material transported is carefully calculated and
controlled by adjusting the speed at which the screw turns.
• very accurate feed values to be maintained
• rotational speed may be preset or constantly adjusted

GRAVIMETRIC SCREW FEEDER

• delivery rate is controlled by adjusting the rate at which the
material is introduced into the machine
Apron Feeders
• a limited-length version of apron conveyor
• also known as plate-belt feeder; plate feeder.
• allows automatic control the volume of
materials that are added to a process
• construct is from heavy, durable materials like
steel
• the belt portion of the apron feeder is made
from thick steel trays or pans
• can be found in mining operations, factories,
and concrete plants
• cannot be used in applications where precise
feeding and measuring is required
1. Materials that will be carried by the
apron feeder are held in a large
hopper above one end of the belt.
The amount of material that reaches
the feeder is determined by the
distance between this hopper and
the top of the feeder.
2. As the hopper deposits materials
onto the apron feeder, the metal
pans that make up the belt travel
horizontally like a conveyor belt.
3. When the trays reach the end of the
belt, they dump, or feed the
materials into another vessel.
Bowl Feeders
• used to feed parts to an assembly line
or piece of manufacturing equipment
• individual components exit the feeder
at specific intervals and enter the next
step in the assembly process
• Each bowl feeder uses special sensors
to spot jams or parts that may be
misaligned.
• one drawback is its precise operation.
How It Works

• In a standard application:
• the bowl feeder sits below a hopper or bin
• workers fill the hopper with bulk material, and these objects fall into
the feeder below
TYPES OF BOWL FEEDERS

Cylindrical
• Material
➢Aluminum/Steel/Stainless Steel
• Suitable for:
➢Continuous transport of components
and for handling small parts
TYPES OF BOWL FEEDERS
Conical

• Material
➢Aluminum/Stainless Steel
• Suitable for:
➢Heavy sharp-edged components
➢Larger Loads
➢Automatic pre-separating
Types of Bowl Feeders

Stepped

• Material
➢Aluminum/Stainless Steel
• Suitable for:
➢Larger loads and larger components
➢Similar to conical bowls
TYPES OF BOWL FEEDERS

Polyamide bowl (conical or stepped)

• Suitable for:
➢Small components with
simple geometry and where mass
production of feeders is required
SAMPLE APPLICATION OF FEEDERS AND SILOS
METHODS, PROCESSES AND
EQUIPMENT INVOLVED IN
HANDLING OF SOLIDS
“CONVEYORS AND CRANES”
CONVEYORS
Conveyors are used:
➢ When material is to be moved
frequently between specific
points
➢ To move materials over a fixed
path
➢ When there is a sufficient flow
volume to justify the fixed
conveyor investment
Conveyors can be classified in different ways:
➢Type of product being
handled: unit load or bulk
load
➢Location of the conveyor:
in-floor, on-floor, or
overhead
➢Whether loads can
accumulate on the
conveyor or no
accumulation is possible
1. Chute conveyor

➢ Unit/Bulk + On-Floor + Accumulate

➢ Inexpensive
➢ Used to link two handling devices
➢ Used to provide accumulation in shipping
areas
➢ Used to convey items between floors
➢ Difficult to control position of the items
2. Wheel conveyor

➢ Unit + On-Floor + Accumulate

➢ Uses a series of skate-wheels mounted on a
shaft (or axle)
➢ Spacing of the wheels is dependent on the load
being transported
➢ Slope for gravity movement depends on load
weight
➢ More economical than the roller conveyor
➢ For light-duty applications Flexible,
(expandable mobile versions available)
3. Roller conveyor

➢ Unit + On-Floor + Accumulate

➢ May be powered (or live) or non-powered (or gravity)
➢ Materials must have a rigid riding surface
➢ Minimum of three rollers must support smallest loads at all times
➢ Tapered rollers on curves used to maintain load orientation
➢ Parallel roller configuration can be used as a (roller) pallet conveyor (more
flexible than a chain pallet conveyor because rollers can be used to
accommodate greater variation of pallet widths)
3(a) Gravity roller conveyor
➢ Alternative to wheel conveyor
➢ For heavy-duty applications
➢ Slope (i.e., decline) for gravity movement depends
on load weight
➢ For accumulating loads

3(b) Live (powered) roller conveyor

➢ Belt or chain driven
➢ Force-sensitive transmission can be used to
disengage rollers for accumulation
➢ For accumulating loads and merging/sorting
operations
➢ Provides limited incline movement capabilities
4. Chain conveyor

➢ Unit + In-/On-Floor + No Accumulation

➢ Uses one or more endless chains on which loads are
carried directly
➢ Parallel chain configuration used as (chain) pallet
conveyor or as a pop-up device for sortation (see
Sortation conveyor: Pop-up devices)
➢ Vertical chain conveyor used for continuous high-
frequency vertical transfers, where material on
horizontal platforms attached to chain link (cf. vertical
conveyor used for low-frequency intermittent transfers)
5. Slat conveyor

➢ Unit + In-/On-Floor + No Accumulation

➢ Uses discretely spaced slats connected to a chain
➢ Unit being transported retains its position (like a belt
conveyor)
➢ Orientation and placement of the load is controlled
➢ Used for heavy loads or loads that might damage a
belt
➢ Bottling and canning plants use flat chain or slat
conveyors because of wet conditions, temperature,
and cleanliness requirements
➢ Tilt slat conveyor used for sortation
6. Flat belt conveyor

➢ Unit + On-Floor + No Accumulation

➢ For transporting light- and medium-weight loads between
operations, departments, levels, and buildings
➢ When an incline or decline is required
➢ Provides considerable control over the orientation and placement
of load
➢ No smooth accumulation, merging, and sorting on the belt
➢ The belt is roller or slider bed supported; the slider bed is used for
small and irregularly shaped items
➢ In 1957, B.F. Goodrich, Co. patented the Möbius strip for
conveying hot or abrasive substances in order to have “both” sides
wear equally
7. Magnetic belt conveyor

➢ Bulk + On-Floor
➢ A steel belt and either a magnetic slider
bed or a magnetic pulley is used
➢ To transport ferrous materials vertically,
upside down, and around corners
8. Troughed belt conveyor

➢ Bulk + On-Floor
➢ Used to transport bulk materials
➢ When loaded, the belt conforms to the
shape of the troughed rollers and idlers
9. Bucket conveyor

➢ Bulk + On-Floor
➢ Used to move bulk materials in a vertical or
inclined path
➢ Buckets are attached to a cable, chain, or belt
➢ Buckets are automatically unloaded at the end
of the conveyor run
10. Vibrating conveyor

➢ Bulk + On-Floor
➢ Consists of a trough, bed, or tube
➢ Vibrates at a relatively high frequency and small
amplitude in order to convey individual units of
products or bulk material
➢ Can be used to convey almost all granular, free-
flowing materials
➢ An Oscillating Conveyor is similar in construction, but
vibrates at a lower frequency and larger amplitude (not
as gentle) in order to convey larger objects such as hot
castings
11. Screw conveyor

➢ Bulk + On-Floor
➢ Consists of a tube or U-shaped stationary trough through which a shaft-mounted helix
revolves to push loose material forward in a horizontal or inclined direction
➢ One of the most widely used conveyors in the processing industry, with many
applications in agricultural and chemical processing
➢ Straight-tube screw conveyor sometimes referred to as an “auger feed”
➢ Water screw developed circa 250 BC by Archimedes
12. Pneumatic Conveyor

➢ Bulk/Unit + Overhead
➢ Can be used for both bulk and unit movement of materials
➢ Air pressure is used to convey materials through a system of vertical and
horizontal tubes
➢ Material is completely enclosed and it is easy to implement turns and
vertical moves
12(a) Dilute-phase pneumatic conveyor

➢ Moves a mixture of air and solid

➢ Push (positive pressure) systems push
material from one entry point to several
discharge points
➢ Pull (negative pressure or vacuum)
systems move material from several entry
points to one discharge point
➢ Push-pull systems are combinations with
multiple entry and discharge points
12(b) Carrier-system pneumatic conveyor

➢ Carriers are used to transport items or paperwork

➢ Examples: transporting money to/from drive-in
stalls at banks and documents between floors of a
skyscraper
13. Vertical conveyor

➢ Unit + On-Floor + No Accumulation

➢ Used for low-frequency intermittent vertical transfers of a load to different
floors and/or mezzanines (vertical chain conveyor can be used for continuous
high-frequency vertical transfers)
➢ Differs from a freight elevator in that it is not designed or certified to carry
people
➢ Can be manually or automatically loaded and/or controlled and can interface
with horizontal conveyors
➢ Alternative to a chute conveyor for vertical “drops” when load is fragile and/or
space is limited
13(a) Vertical lift conveyor

➢ Series of flexible conveyor-carriers rotate

in a loop, where empty carriers flex
perpendicularly to provide access to
loaded carriers moving past them in
opposite direction
13(b) Reciprocating vertical conveyor

➢ Carrier used to raise or lower load

➢ Can be powered (hydraulic or
mechanical) or non-powered
➢ Non-powered version only be used to
lower a load, where counterweight used
to return empty carrier to top
14. Cart-on-track conveyor

➢ Unit + In-Floor + Accumulate

➢ Used to transport carts along a track
➢ Carts are transported by a rotating tube
➢ Drive wheel connected to each cart rests on tube and
is used to vary the speed of the cart (by varying angle
of contact between drive wheel and the tube)
➢ Carts are independently controlled
➢ Accumulation can be achieved by maintaining the
drive wheel parallel to the tube
15. Tow conveyor

➢ Unit + In-Floor + Accumulate

➢ Uses towline to provide power to wheeled carriers such as
trucks, dollies, or carts that move along the floor
➢ Used for fixed-path travel of carriers (each has variable path
capabilities when disengaged from towline)
➢ Although usually in the floor, the towline can be located
overhead or flush with the floor
➢ Selector-pin or pusher-dog arrangements used to allow
automatic switching (power or spur lines)
➢ Generally used when long distance and high frequency
moves are required
16. Trolley conveyor

➢ Unit + Overhead + No Accumulation

➢ Uses a series of trolleys supported from or
within an overhead track
➢ Trolleys are equally spaced in a closed loop
path and are suspended from a chain
➢ Carriers are used to carry multiple units of
product
➢ Does not provide for accumulation
➢ Commonly used in processing, assembly,
packaging, and storage operations
17. Power-and-free conveyor

➢ Unit + Overhead/On-Floor + Accumulate

➢ Similar to trolley conveyor due to use of
discretely spaced carriers transported by an
overhead chain; however, power-and-free
conveyor uses two tracks: one powered and the
other nonpowered (or free)
➢ Carriers can be disengaged from the power
chain and accumulated or switched onto spurs
➢ Termed an Inverted Power-and-Free Conveyor
when tracks are located on the floor
18. Monorail

➢ Unit + Overhead + Accumulate

➢ Overhead single track (i.e., mono-rail) or track network on
which one or more carriers ride
➢ Carriers: powered (electrically or pneumatically) or non-
powered
➢ Carrier can range from a simple hook to a hoist to an
intelligent-vehicle-like device
➢ Single-carrier, single-track monorail similar to bridge or gantry
crane
➢ Multi-carrier, track network monorail similar to both a trolley
conveyor, except that the carriers operate
19. Sortation conveyor

➢ Unit + On-Floor/Overhead
➢ Sortation conveyors are used for merging, identifying, inducting, and separating products to be
conveyed to specific destinations. Sortation system throughput is expressed in cartons per
minute (CPM). A sortation system is composed of three subsystems:
➢ Merge subsystem—items transported from picking (storage) or receiving areas on conveyors
and consolidated for proper presentation at the induct area.
➢ Induct subsystem—destination of each item identified by visual inspection or automatic
identification system (e.g., bar code scanner), then a proper gap between items is generated
using short variable speed conveyors as they are released to the sort subsystem.
➢ Sort subsystem—items are diverted to outbound conveyors to shipping, palletizing, staging,
and/or secondary sort subsystems.
There is a trend towards more use of mixed-item loads that eliminate the need for
sortation: instead of a producer sending pallet loads of a single item to a
distribution center for subsequent sortation or consolidation into multi-item
customer loads, single pallets can be loaded at a producer with a different mix of
items for each customer. This also can enable greater use of cross docking.
19(a) Sortation conveyor: Diverters
➢ Stationary or movable arms that deflect, push, or pull a product to desired destination
➢ Since they do not come in contact with the conveyor, they can be used with almost
any flat surface conveyor
➢ Usually hydraulically or pneumatically operated, but also can be motor driven
➢ Simple and low cost
19(b) Sortation conveyor: Pop-up devices
➢ One or more rows of powered rollers or wheels or chains that pop up above surface of
conveyor to lift product and guide it off conveyor at an angle; wheels are lowered when
products not required to be diverted
➢ Only capable of sorting flat-bottomed items
➢ Pop-up rollers (not shown) are generally faster than pop-up wheels
19(c) Sortation conveyor: Sliding shoe sorter

➢ Sliding shoe sorter (a.k.a. moving slat sorter)

uses series of diverter slats that slide across
the horizontal surface to engage product and
guide it off conveyor
➢ Slats move from side to side as product flows
in order to divert the product to either side
➢ Gentle and gradual handling of products
19(d) Sortation conveyor: Tilting device

➢ Trays or slats provide combined sorting

mechanism and product transporter
➢ Can accommodate elevation changes
➢ Tilt tray sorters usually designed in continuous
loops with compact layout and recirculation of
products not sorted first time
➢ Tilt slat sorters carry products on flat-surface slat
conveyor and can handle wider variety of
products compared to tilt tray
19(e) Sortation conveyor: Cross-belt transfer device

➢ Either continuous loop, where individual carriages are

linked together to form an endless loop, or train style
(asynchronous), where a small number of carriers tied
together with potential for several trains running track
simultaneously
➢ Each carriage equipped with small belt conveyor, called
the cell, that is mounted perpendicular to direction of travel
of loop and discharges product at appropriate destination
➢ Automatically separates single line of products into
multiple in-line discharge lines
Cranes
1. Jib crane

➢ Horizontal boom (jib) supported from a

stationary vertical support
➢ Hoist can move along the jib and can be
used for lifting
➢ Operates like an arm in a work area,
where it can function as a manipulator for
positioning tasks
➢ Jib can also be mounted on the wall
➢ Arm can rotate up to 360°
2. Bridge crane

➢ Bridge mounted on tracks that are located

on opposite walls of the facility
➢ Enables three-dimensional handling
➢ Top riding (heavier loads) or underhung
(more versatile) versions of the crane
➢ Underhung crane can transfer loads and
interface with other MHS (e.g., monorail
systems)
3. Gantry crane

➢ Single leg, double leg, and mobile types of

gantry cranes
➢ Similar to a bridge crane except that it is floor
supported at one or both ends instead of
overhead (wall) supported
➢ Used to span a smaller portion of the work
area as compared to a bridge crane
➢ The supports can be fixed in position or they
can travel on runways
➢ Can be used outdoors when “floor” supported
at both ends
4. Stacker crane

➢ Similar to a bridge crane except that, instead of a

hoist, it uses a mast with forks or a platform to
handle unit loads
➢ Considered “fork trucks on a rail”
➢ Used for storing and retrieving unit loads in
storage racks, especially in high-rise applications
in which the racks are more than 50 feet high
➢ Can be controlled remotely or by an operator in a
cab on the mast
➢ Can be rack supported
End…
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